Method of manufacture of fluid separation apparatus



METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS Filed D90. 22, 19%5y 6, 1969 J. E. GEARY, JR., ET AL REGO RlDHARDpDDLD Sheet JAMES EDWARDGEARY, JR, WILLIAM EDWARD HARSCH JOHN HURDODK MAXWELL .2 :Nnik

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METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS Filed Dec. 22, 19652 of'lO Sheet FIG-6 2|9 PRODUCT 1ST STAGE FEED SWEEP EFFLUENT RECYCLEINVENTORS .IA EDWARD GEARY, JR. WILLIAM EDWARD HARSCH JOHN IIURDOCKIAXIELL RICHARD DONALD REGO I, I ATTQRNEY y 1969 J. E. GEARY, JR., ET ALMETHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS Filed Dec. 22, 19653 oflO Sheet INVENTORS V. R isu n v R nu RAVE HXR E A G DAKA QC A000 EF- D 4 R 4 5' A ELNH ".L c AIOI r JWIJR May 6, 1969 J GEARY, JR" ET AL3,442,002

METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS Filed Dec. 22, 1965Sheet s w H R as m mm v mmmu a 3 o 35 2; E ea K A c .z DDAWMM flp J z Do o W U w Z E l A l 3 E s22: N 1 L Mmwm E5: x o 2 \o W is w E 8 m 02 5 Ew: E5 5 962$ 52 mg a? 5 E J V :K 2 5, E A 2;; 2:; E25 2. A 225:: 1;3:35.: fisz omwm x afi 5 02 N2 :5 a. )3

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METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS File' d Dec. 22,1965 Sheet FEED E 4 TN 6 w an 6, uw m r. an n 6 PP 0 M 6 s e @6 6 0. V V4 6 v x 5 0 0 6 6 5 M 6 m M S 6 1 6 6 b V 3 m 1 4 2 4 s m an m w u m s 66 6 6% B L A 45 I I u \1 5% 7 0 w W 6 7 6 3 I, I o 3 2 no 0 .D :J 2 6 .mA L 6 6 7 L .l M 2 4 7 3 6 r e w 5 1 2 w w 4 s 5 2 3 6 6 0 4 2 m 2 6 0 m9 6 ll 6 6 6 6 6 6 MS 7 D "M J Q E F 6 H E INVENTORS JAMES y 1969 J. E.GEARY, JR, ET AL 3,442,002

METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS I Flled Dec. 22,1965 A M i May 6, 1969 J, GEARY, JR ET AL 3,442,002

METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS Filed Dec. 22, 1965Sheet 8 of 10 F! .13 m FIG. I4

y 1969 J. E. GEARY, JR, ET AL 3,442,002

METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS Filed Dec. 22, 1965Sheet 9 of 10 9I9b J; 907 905b II/IIIIII'III/ F I G. 9 INVENTORS JAMESEDWARD GEARY, JR. WILLIAM EDWARD HARSCH JOHN MURDOCK MAXWELL RICHARDDONALD REGO ATTORNEY May 6, 1969 J. E. GEARY, JR., ET AL METHOD OFMANUFACTURE OF FLUID SEPARATION APPARATUS Filed Dec. 22, 1965 Sheet 0 of10 e s g 2 1 m g 5 D x4 2 $3 2 I c c l g J/ fi-I-EEfl Q fig JT'" 1" =4:

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o ||'*T h H====H \|l --J\:-|F5: ::{]I 5' \Q i g 1 g E D/ 2 I s g i I 1 Dd g I? INVENTORS JAMES EDWARD GERRY, JR. WILLIAM EDWARD HARSCH JOHNHURDDCK MAXWELL RICHARD DONALD REGD Y ATTORNEY United States Patent3,442,002 METHOD OF MANUFACTURE OF FLUID SEPARATION APPARATUS JamesEdward Geary, Jr., Claymont, Del., William Edward Harsch, Stauntou, Va.,John Murdock Maxwell, Glen Farms, Md., and Richard Donald Rego,Wilmington, Del., assiguors to E. I. du Pout de Nemours and Company,Wilmington, Del., a corporation of Delaware Filed Dec. 22, 1965, Ser.No. 515,535 Int. Cl. B01d 13/00; C02b 1/60 US. Cl. 29450 13 ClaimsABSTRACT OF THE DISCLOSURE A manufacturing arrangement, for producing adifferential permeation fluid separation unit of the type comprising anelongated tubular casing assembly each end of which is closed by afluid-tight centrifugally cast wall member of polymeric composition,said unit further comprising a bundle of very small diameter filamentsof polymeric composition positioned in the casing, said filamentsmaintained substantially parallel and in a compact bundle by a flexibleporous sleeve member extending along said bundle and having hollowinterior portions and open end portions extending through portions andopen end portions extending through thewall members, said bundle formedfrom a hank of continuous hollow filaments, said bundle having endportions each comprising a plurality of loops of said continuousfilaments as they traverse the bundle, the ends of the bundle havingbeen encapsulated in a centrifugally cast wall member at the ends of acasing member in which the bundle is positioned and the end portion ofthe bundle then having been severed to expose the open ends of theencapsulated hollow filaments.

This invention relates generally to the field of separating fluids byutilizing their different permeation rates through membrane elements inthe form of small hollow filaments made of organic polymericcompositions. More specifically, the invention involves novel andimproved process arrangements for the production or fabrication of thefluid separation apparatus of the invention.

Fluid separation apparatus and methods utilizing hollow filaments ofpolymeric compositions have been disclosed in the prior art. However,careful examination of such disclosures indicates that the apparatus andprocess arrangements represented experimental or ineflicient, im-

practical embodiments of the early ideas in this field. In

addition, such prior art arrangements were of such designs and possessedfeatures which would not lend themselves either to effective commercialoperation or to practical, reliable commercial manufacturing techniques.

It is an object of the invention to provide new and improved commercialmanufacturing procedures for producing the fluid separation apparatus ofthe invention.

The means and methods by which the objects of the invention areachieved, as well as additional objects and advantages thereof will beapparent from a consideration of the following specification and claimstaken in conjunction with the accompanying drawings in which:

FIGURE 1 is a partial longitudinal sectional view of the fluidseparation unit of this invention with parts broken away to show thedetails of its construction.

FIGURES 2 and 2a are partial transverse cross-sectional views taken atline 22 of FIGURE 1, FIGURE 2a being somewhat enlarged.

FIGURE 3 is a partial transverse cross-sectional view taken at line 3-3of FIGURE 1.

FIGURE 4 is a partial greatly enlarged transverse 3,442,002 Patented May6, 1969 cross-sectional view of an indicated portion of a group ofhollow filaments of the unit shown in FIGURE 2.

FIGURES 5a, 5b, 5c, and 5d are partial showings of illustrative poroussheath members used to surround and constrain the filaments in thegroups and bundles.

FIGURE 6 is a schematic diagrammatic showing of a two stage permeationseparation system or arrangement utilizing permeation separation unitsof the type shown in FIGURE 1.

FIGURE 7 is a schematic diagrammatic showing of a three stage permeationseparation system or arrangement utilizing permeation separation unitsof the type shown in FIGURE 1.

FIGURE 8 is a schematic diagrammatic showing of a modified three stagepermeation separation system or arrangement utilizing permeationseparation units of the type shown in FIGURE 1.

FIGURE 9 is a schematic diagrammatic showing of a four stage permeationseparation system or arrangement utilizing permeation separation unitsof the type shown in FIGURE 1.

FIGURE 9a is a schematic diagrammatic showing of a preferred arrangementof a plurality of fluid separation units in one stage of a fluidseparation system embodying principles of the invention invention.

FIGURE 10 is a general somewhat schematic perspective view of anapparatus arrangement for forming individual groups of small filamentsin the form of hanks, bundles or loops of continuous hollow filaments.

FIGURE 11 is a simple side elevational view of a single hank or loop ofcontinuous hollow filaments in elongated flattened configuration whichforms a group or sub-bundle for eventual assembly in the permeationseparator unit embodying principles of this invention.

FIGURE 12 is a simple side elevational view showing a single hank orloop of continuous hollow filament in elongated flattened configurationbeing encased in and radially constrained by an elongated porous sheathmember to make an encased group or bundle.

FIGURE 13 is a partial side elevational view showing a plurality ofgroups or sub-bundles of hollow filaments, each encased in its poroussheath member, being assembled to form the larger bundle beforepositioning of the larger bundle in the casing of -a permeationseparator unit of the invention.

FIGURE 14 is a partial elevational view of a bundle of assembled groupsof sheath encased hollow filaments in position for movement into theunit casing after the final porous sheath member or members ispositioned around the assembled bundle.

FIGURE 15 is a view similar to FIGURE 14 showing a final porous sheathmember being positioned on a bundle of assembled filament groups toradially constrain the same to dimensions which permit positioning ofthe assembled bundle in the unit casing.

FIGURE 16 is a partial longitudinal sectional view of a bundle ofassembled filament groups in position in the unit casing with a moldassembly operatively mounted on the casing for formation of a cast endclosure member for the unit casing.

FIGURE 17 is a view similar to FIGURE 16 showing the completed cast endclosure member positioned in the unit casing with the mold assemblyremoved and before the unwanted excess portions of the cast end closuremember is cut away.

FIGURE 18 is a view similar to FIGURE 17 of a completed modified castend closure member positioned in unit casing as in FIGURE 17, the castend closure member being the type formed against a radially outwardlypositioned layer of heavy immescible liquid in the mold assembly duringcentrifuging in order to maintain the ends of the bundle of filamentsfree of the cast material.

FIGURE 19 is a partial perspective view of a centrifuging apparatus usedin forming the east end closure member for the permeator separator unitcasing, showing a casing and cooperating mold assemblies in operativeengagement with the centrifuging apparatus.

FIGURE 20 is a partial side elevational view of a modified version ofthe centrifuging apparatus shown in FIGURE 19 showing a plurality ofunit casings in position for formation of one of their cast end closuremembers.

A basic unit of fluid separation apparatus representing a preferredembodiment of the invention is shown in FIGURES 1, 2, 3, and 4 of thedrawings. Generally speaking, this apparatus depends, for its operation,on the selective passage of gases and liquids through nonporous membraneelements by permeation or activated diffusion. Such passage is usuallypictured as involving solution of gaseous or liquid material into onesurface of a solid nonporous membrane element, migration of the materialthrough the membrane element under the influence of a difference inconcentration or pressure, and emergence of the material from anothersurface of the membrane element. Separation is obtained when differentcomponents of a fluid mixture pass through the non-porous membraneelement at different rates. This type of separation involvingdifferential permeation has been achieved, according to the known priorart, in membrane elements of platinum, palladium and their alloys; inmembrane elements of silica and certain glasses; and also in membraneunits of various polymeric materials.

The preferred apparatus shown in FIGURES 1-4 comprises an elongatedfluid-tight tubular casing assembly 101 formed of a suitable materialsuch as steel. Tubular casing assembly 101 is preferable open at bothends. Both ends are provided with flange elements 102 and outwardlytapered portions 107. In addition the tubular casing assembly isprovided with inlet and outlet means 108 and 109 to provide for movementof fluid into and out of the assembly. Preferably, means 108 and 109communicate with the enlarged interior portion of the tubular assemblyformed by tapered portions 107. A plurality of very small hollowfilaments 111, of polymeric composition, such as polyethyleneterephthalate for example, are positioned inside the tubular casingassembly 101 in a relatively close-packed relationship. As shown in FIG-URES 1-4 the plurality of filaments 111 comprises a number ofsubstantially equal groups 110 of filaments each group firmlyperipherally constrained by an elongated flexible porous sleeve member112 extending longitudinally of the filaments and the groups. Inaddition, the groups 110 of filaments each surrounded by their poroussleeve members are all surrounded by at least one overall elongatedflexible porous sleeve member 113 as shown. The detailed constructionand functioning of these sleeve members will be discussed at a laterpoint in this specification. Each end of the tubular casing assembly 101is closed by a fluid-tight cast wall member 950 preferably formed ofpolymeric composition, such as an epoxy resin, for example. The hollowfilaments, substantially parallel to each other and to the axis of thetubular casing assembly, extend between the cast wall members 950. Thehollow filaments have open end portions which are embedded in and extendthrough the cast wall members in fluid-tight relation thereto. Thetubular casing assembly 101 is further provided at each end with outerclosure members 103 which cooperate with the tubular casing assembly 101and the cast wall members 950 to define a closed chamber 130 incommunication with the interior portions of the hollow filaments. Eachchamber 130 is provided with conduit means 104 to permit movement offluid between each chamber and a point outside the chamber. The outerclosure members 103 are provided with flanges 105 which are secured tothe flanges 102 of the tubular casing assembly by means of belts 106. In

' the preferred embodiment shown, an annular resilient gasket K ofsuitable material such as rubber neoprene is provided between the castwall members 950 and the tubular casing assembly 101 and between thecast wall members and outer closure members 103 to improve thefluid-tight sealing action. The outer closure members 103 are formed ofa suitable material such as steel, for example.

As shown in FIGURE 2, the sleeve-encased groups of filaments 111positioned in the main portion of the tubular casing assembly betweenthe tapered portions 107 are relatively closely packed. The flexibleconstraining nature of the porous sleeve members 112 maintains thefilaments in each group in a compact cross section while permitting eachgroup to yieldably engage the other groups and the inside of the tubularcasing assembly, in order to accommodate where necessary the crosssectional deformations necessary to achieve a packing condition of ahigher degree than could be obtained by groups of rigid circulartransverse cross sections. This is best shown in FIGURE 2a. The filamentgroups and the filaments themselves engage each other, and the casingassembly, laterally in a number of elongated areas or lines extendingalong the length of the groups and filaments (FIGURES 2, 2a, and 4).These elongated areas define between the groups, between the filaments,and between the groups and the interior of the casing assembly, aplurality of transversely evenly distributed elongated passagewaysextending along the length of the filaments and the tubular casingassembly. These passageways have very little lateral communication, andforce circulation of fluid in the casing assembly and outside the hollowfilaments to move substantially longitudinally along the filaments andthe interior portion of the tubular casing assembly between the taperedportions 107.

A positional relationship of the filament groups adjacent their ends andresulting from the tapered portion 107 of the tubular casing assembly,is shown in FIGURE 3. It will be seen in this figure that the enlargedinterior cross section at the tapered portion 107 reduces the packingdensity of the filament groups and increases the spacing between them topermit improved distribution and collection of fluid between the inletand outlet means 108, 109 and the elongated passageways between theadjacent filaments, and groups of filaments.

The interior tapered end portion 107 of each end of the tubular casingassembly 101 cooperates with the corresponding tapered portion of thecast wall member 950 to develop a wedging action to help maintain thefluidtight seal between these parts. A similar action occurs as a resultof the engagement between the engaged tapered portions of outer closuremember 103 and the cast wall member 950.

An important feature of the apparatus involves the inner face SF of thecast wall members 950. This surface is relatively smooth, continuous,even, and substantially free of sharp deviations in the direction alongwhich the hollow filaments extend. It is important that thisconfiguration be achieved and maintained so that a fluidtight sealexists around the hollow filaments without diminishing the effectivesurface area of the filaments between the cast wall members. In apreferred embodiment of the invention, the inner surface SF of the castWall members 950 has a concave curved configuration of a right circularcylinder, as shown. This configuration results from the centrifugalcasting operation preferably employed to form the cast wall member 950and which will be described in detail hereinafter.

The hollow filaments 111 may be composed of any polymeric material whichis suitable for selective or differential permeation fluid separations.They may be made of olefin, ester, amide, silicone, ether, nitrile, orsulfide polymers; or of any other suitable polymer or copolymer.

Suitable hollow filaments can be made from polyethylene terephthalate,polyvinyl chloride, polyvinylident chloride, polyhexamethyleneadip-amide, copolymers of tetrafluoroethylene and hexafluoropropylene,cellulose acetate, ethyl cellulose, polystyrene, copolymers of butadieneand styrene and many other polymers and copolymers. The filaments may beprepared in any suitable manner, such as by solution spinning or by meltspinning. The hollow polymeric filaments are preferably between aboutand about 500 microns in outside diameter and preferably have wallthicknesses between about 1 and about 100 microns. Hollow filamentsbetween and 250 microns in outside diameter with wall thicknessesbetween 2 and 50 microns are especially preferred.

The density of packing of the hollow filaments 111 within the flexibleporous sleeve members 112 may for practical purposes be of anyconvenient value above about 35%, but for optimum results should be ashigh as practicable. Packing density is defined as the percentage of thecross sectional area which is enclosed within the outer walls of thehollow filaments inside the tubular casing assembly 101. For a housingassembly of circular transverse cross section of inside diameter Dcontaining N hollow filaments of circular cross section and outsidediameter D the packing density is given as follows:

The packing density defined in this way has a maximum value of 90.5% forcircular cross section hollow filaments in a hexagonally close packedarrangement and maximum value of 78.5% for square close packing. Packingdensities above 45% inside the flexible porous sleeve members have beenachieved without difficulty. Packing densities up to 60% or more can beobtained by maintaining the filaments parallel, surrounding them by asleeve member, and reducing the peripheral dimension of the sleevemember to compact the filaments contained therein. When groups ofsleeve-encased compacted filaments have been bundled and drawn intotubular casing assemblies as shown in the drawings, packing densities ofabout 55% have been achieved. Overall packing densities above about 40%are preferred in the permeation units of the type shown in FIGURES 1-4.These high packing densities do not prevent all movement of fluid intoand out of the bundles between the filaments, but they do cause thefluids outside of the hollow filaments in the tubular casing assembly toflow along and in the direction of the filaments in a given group orbundle. This flow condition causes desirable concentration gradients tobe established and maintained inside the housing assembly along thehollow filaments when a fluid mixture is passed through the hollowfilaments in the housing assembly. This will be discussed in more detailat a subsequent point in the specification.

The flexible porous sleeve members 112, 113 may be made of any suitablematerial, natural, reconstituted, or synthetic, of suitable strength andcompatible with the fluid mixture being handled, the polymer from whichthe hollow filaments are made, the material forming the cast wallmembers, and the other materials with which the sleeve will come incontact. The sleeve members may be of any practical construction whichis porous and flexible. Preferably the sleeve members should be of astrong abrasion resistant material, or a construction, which is capableof shrinkage or shortening at least in the transverse peripheraldimension to give a uniform constraining compacting action on and alongan enclosed bundle or group of filaments. A preferred constuction is acircularly knit fabric sleeve of a suitable material such as cottonthread, for example which sleeve is capable of considerable reduction intransverse peripheral dimension when the sleeve is placed under tensionlongitudinally. This sleeve is especially advantageous, for when tensionis exerted on such a sleeve surrounding a bundle to pull a fila- Packingdensity (percent) ment bundle into a tubular casing assembly, thetension also results in uniformly compacting and reducing the bundlecross section along the bundle length to facilitate positioning thebundle in such a casing assembly without flattening or damaging thefilaments of the bundle. The sleeve members 113 may also be made ofwoven, or nonwoven fabric, or of punched or cut cylindrical tubes, ortubes of netting as shown in FIGURES 5a, 5b, 5c, and 5d. The ability ofthe sleeve member to shrink or reduce its radius or circumferenceuniformly and evenly is highly desirable and important.

The tubular casing assembly may be made with any suitable transversecross sectional configuration and of any suitable compatible material ofsuflicient strength. Cylindrical metallic housings, for example; steelpipe, are satisfactory, being reasonably easy to produce and assemble.The size of the tubular casings of the separation apparatus units mayvary from less than one inch to many inches in outside diameter, and mayvary from a few feet to many feet in length.

An idea of the effective construction and use of hollow filaments in theapparatus of this invention may be indicated by the fact that in aseparation apparatus embodying features of this invention and having atubular casing assembly about six inches in diameter and eight feetlong, about twelve million hollow filaments have been packed to give aneffective membrane surface area of about 20,000 square feet.

In certain forms of the fluid separation apparatus of this invention, itis desirable to introduce fluid adjacent each end of the tubular casingassembly (see final stage of FIGURE 8) and remove fluid from theassembly at a position intermediate its ends. Under these circumstances,it is desirable to provide an enlarged interior cross section for theassembly at this position intermediate its ends to reduce the packing ofthe filaments and filament groups for a limited distance to permitlateral flow and collection of fluid from between the filaments andfilament groups.

The cast end closure members 950 may be made of any convenient settableor solidifiable material of sufiicient strength and compatibility withthe other parts of the apparatus. Solders, cements, waxes, adhesives,natural and synthetic resins may be used. This cast wall member materialmay set or solidify because of freezing or cooling, or because ofcooling, or because of chemical reactions which cause polymerization,condensation, oxidation, or other hardening processes. Other desirableproperties of the settable or solidifiable material are: a low viscosityin the liquid form to promote easy penetration of filament bundles priorto solidification or setting, a high density to perform better under thecentrifugal casting action (to be described in detail hereinafter),absence of gas evolution or similar physical change duringsolidification, minimum or no change in volume during solidification,and minimum evolution of heat during solidification. Synthetic organresins are well suited for use as setting materials with the preferredpolymeric compositions of the hollow filaments. The preferred materialsfrom which the cast wall members are formed are epoxy resins.

In describing the operation and functioning of the apparatus unit shownin FIGURES l-4, the description will first be given of the unitoperating as first stage unit in a multi-stage system. In use as a firststage unit for the enumerated separations of gases (where the componentwith the highest permeation rate through the hollow filament walls to beseparated from a fluid mixture represents only a small percentage of themixture), it has been found advantageous to move the initial mixturethrough the interior of the hollow filaments and collect the permeatedfluid from the outside of the hollow filaments. With respect to FIGURE1, this general procedure is accomplished by bringing the inlet streamof the initial fluid mixture at elevated pressure into chamber at the 7left hand end of the apparatus, as viewed in FIGURE 1, through conduitmeans 104. From this chamber 130, the fluid mixture then moves throughthe interior portions of the hollow filaments of filament groups 110 toa similar chamber 130 at the right hand end of the apparatus as seen inFIGURE 1. With a suitable pressure and/or concentration differentialmaintained between the inside and outside of the hollow filaments, afraction of the initial fluid mixture enriched in the component with thehighest permeation rate will permeate outwardly through the walls of thehollow filaments into the space between the inside of tubular casingassembly 101 and outside of the hollow filaments. The resulting fluidmixture, or eflluent, which reaches the chamber 130, somewhat depletedin the component with the highest permeation rate through the filamentwalls, is removed through conduit means 104.

The enriched fraction of the initial fluid mixture, or permeate product,which has permeated through the walls of the hollow filaments may thenbe removed from the interior of tubular casing at a lower pressurerelative to that of the inlet stream, through a suitable outlet meanssuch as 108. The preferred mode of operation involves the use of a sweepfluid stream, which may be a portion of the inlet stream at lowerpressure, moved into the casing assembly 101 through inlet means 109,along the outside of the hollow filaments in the casing assembly, andout through outlet means 108. Sweep fluid flow in a directioncountercurrent to the inlet stream flow is preferred in order tomaintain desirable eflective concentration gradients. Under theseconditions, the close packing of the filaments and groups, which is madepossible by the sleeve members 112, 113, together with the resultinglongitudinally extending passageways between the filaments and groups,as discussed previously, result in highly eflicient evenly distributedfluid flow patterns inside casing assembly 101 and outside the hollowfilaments in which flow patterns undesirable back mixing of the fluidoutside the hollow filaments, and disturbance of the desirableconcentration gradients is kept to a low minimum. In addition, the largeamount of effective membrane surface area present per unit volume of thecasing assembly in its extremely small thickness, also contributesimportantly to the eflicient, practical, economically feasible fluidseparation rates of this apparatus.

Under conditions in which the fluid mixture component to be separated(with the highest permeation rate through the hollow filament walls)represents a large percentage of the mixture, it has been founddesirable to introduce the initial fluid mixture under elevated pressureinto the interior of the tubular casing assembly 101 and outside of thehollow filaments through inlet means 109 and remove it as the efliuentstream from outlet means 108 in condition depleted of its highestpermeation rate component. In this mode of operation, a fraction of theinitial fluid mixture enriched in the component with the highestpermeation rate will permeate inwardly through the hollow filament wallsinto the interior of the hollow filaments from which it may be removedat lower pressure through conduit means 104 and/or 104' after beingcollected in chambers 130 and 130'. It is also desirable in this mode ofoperation to utilize a sweep fluid moving countercurrently to the flowof the initial fluid mixture, bringing it in through conduit means 104and removing it and the permeate product through conduit means 104. Thismode of operation has been found advantageous for the final stageapparatus units of a multi-stage gas separation system. However, it isunderstood that in other applications of the invention, such as waterdesalinization, or hydrocarbon separations other arrangements may bemore advantageous.

Another desirable final stage version involves supplying the inlet fluidmixture into the casing assembly outside the hollow filaments at a pointadjacent each end of the assembly and removing the depleted inletmixture from the casing at a point between the ends of the casing (FinalStage FIGURE 8). In this version the fluid which permeates into theinterior of the hollow filaments is removed simultaneously from bothends of the apparatus (Final Stage FIGURE 8). It will be noted that thisestablishes the desirable countercurrent flow of permeated fluid andinlet fluid mixture with its desirable concentration gradients.

With the preferred materials of construction, these apparatus unitsembodying principles of the invention can be operated satisfactorily atordinary atmospheric temperatures and at moderate pressure levels, wellbelow 1000 pounds per square inch for example, although the hollowfilaments will easily sustain sufficiently high pressure differentialsto give commercially required flow rates. The flexible porous sleevemembers 112, 113 which surround the groups of filaments not only serve avery useful purpose during assembly of the fluid separation apparatus ofthe invention but are important as a part of the apparatus combinationitself in that they also continue to protect the hollow filaments duringoperation and function to maintain the lateral, or transverse,compressive stresses substantially evenly distributed throughout theentire bundle of closely packed hollow filaments without flattening ordamaging the hollow fllaments, even those at the outer periphery of thebundle in contact with the tubular casing assembly walls.

The preferred use of centrifugally cast wall members to close the casingassembly ends and seal around the filaments is believed to be extremelyimportant to the overall apparatus combination in achieving an eflectiveuniform fluid-tight wall and seal between those filaments and the casingassembly, without wicking of the wall material (when in liquid form)between and along the filaments due to capillary action which couldcause voids in the wall and would, by coating the filament surfaces,reduce the eflective membrane area within the casing assembly forpermeation and separation.

The apparatus unit shown in FIGURES l-4 can be combined in various formsand ways to provide many different multi-unit and multi-stage separationsystems if desired or required. A number of such systems are shown inFIGURES 6, 7, 8, 9, and 911.

FIGURE 6 shows one of the most simple forms of a multi-stage gasseparation system embodying features of the invention, a two stagesystem in which a supply conduit 201 supplies a feed or inlet stream toa pressure regulating valve 202 from which the inlet stream is passedvia conduit 203 through the hollow filaments of a first stage separationapparatus unit 100, of the type shown in FIGURE 1. Conduit 204 conductsthe depleted stream or etfluent which has passed through the hollowfilaments of the first stage separation apparatus unit to a pressureregulating valve 206 from which the efliuent stream may be vented,recycled, or otherwise disposed of. A conduit 210 carries a portion ofthe feed inlet stream to control valve 208 from which the stream ispassed into the casing assembly of the first stage separation unit 100as a sweep fluid by conduit 209. Control valve 208 is controlled by afluid analyzer unit 207 which is connected to analyze the effluent fluidcomposition in conduit 204. The sweep fluid and permeated fluid areremoved from the first stage casing assembly through conduit 211 andsupplied to compressor unit 212 which raises its pressure prior to beingsupplied via conduit 213 to the interior of the hollow filaments ofsecond or final stage separation apparatus 100. The fluid from theinterior of the hollow filaments of final stage apparatus 100 is passedalong conduit 214 and 215 to control valve 218 and thence throughconduit 216 is recycled into the inlet stream to the first stageseparation unit. Control valve 218 is controlled by a fluid analyzerunit 217 which is connected to analyze the composition of the recycledeflluent stream from the second stage separation unit. Permeated fluidis removed from the second stage casing assembly through conduit 219 asthe final permeate product. Fluid analyzer unit 220 analyzes thecompositions of the final product fluid and is operatively connected toanalyzer unit 217 as will be discussed at a later point.

In operating this system of FIGURE 6, automatic control, or pressureregulating valves 202 and 206 maintain the feed fluid and efliuent fluidpressures at desired values. Fluid analyzer unit 207 determines theconcentration of the more permeable components of the process fluid inthe depleted eflluent fluid and operates control valve 208 to maintain adesired constant low concentration. Thus, if the eflluent concentrationbecomes too high, control valve 208 is opened to increase the sweepfluid flow; if too low, the sweep fluid flow is decreased. Similarly,fluid analyzer 217 determines the concentration of the more permeablecomponents in the recycle fluid and operates control valve 218 tomaintain a constant concentration, which is set or determined byanalyzer unit 220 of the product stream. If the concentration of therecycle fluid becomes too high, analyzer unit 217 causes control valve218 to close to reduce the flow of the recycle fluid, thereby increasingthe fraction of the inlet fluid to the second stage unit which permeatesthrough the hollow filament membranes and reducing the concentration ofthe more permeable components in both recycle and product fluids.Similarly, if the concentration of the product fluid becomes too low inthe more permeable components, analyzer 220 raises the set point ofanalyzer unit 217 which in turn causes control valve 218 to open toincrease the recycle flow rate, reducing the fraction of inlet fluid tothe second stage unit which permeates and increasing the concentrationof the more permeable components in both recycle and product fluidstreams.

In operating a two stage separation system of the FIGURE 6 type toconcentrate helium in a mixture of helium and nitrogen, a gas mixturecontaining 0.47% helium were compressed to 400 p.s.i.g. and combinedwith a recycle stream described below. The resulting feed gas (5315standard volumes per minute) was passed into a separation apparatus unitof the type shown-in FIGURE 1 having hollow filament membranes composedof poly(ethylene terephthalate). The feed gas was passed into one end ofthe apparatus, through the interior of the hollow filament-s, and outthe other end of the apparatus. A portion of the starting gas wasreduced in pressure to 9.8 inches of mercury and passed as a sweep gasinto the tubular casing assembly of the unit near its exit end. Thedepleted eflluent gas which had passed through the interior of thehollow filaments of the first stage contained 0.047% helium for arecovery of 90%. The combined permeate and sweep gas (693 volumes perminute) from this first stage unit contained 3.6% helium. This combinedpermeate and sweep gas was compressed to 450 p.s.i.g. and passed throughthe interior of the hollow filament membranes of the second stage unit(also of the type shown in FIGURE 1) 242 volumes per minute. Afterpassing through the interior of the hollow filaments of the second stageunit, the depleted recycle stream contained 1.63% helium at a pressureof 438 p.s.i.g. The permeate product taken from the inlet end of thetubular casing assembly of the second stage unit (8 volumes per minute)contained 63.0% helium. The recycle gas was combined with the startinggas mixture to make the feed to the first stage unit.

Systems of this type can be used with suitable hollow filament membranecompositions to obtain air enriched with oxygen, to recover hydrogen ofincreased purity from its mixture with other gases, to separate methanefrom other hydrocarbons, and for other separations.

FIGURE 7 shows a somewhat more elaborate system than that of FIGURE 6and embodying principles of the invention preferably used forrepurifying helium or recovering oxygen from air. This three stagesystem comprises nine compressors C, in three sets, all preferablydriven by suitable means such as electric motors, each set associatedwith one or more permeation apparatus units at each of the three stages.The initial or feed stream moves through conduit 301 to a samplingdevice S thence to a flow rate measuring device R and n through conduit302 to pressure gage G and the first stage compressor C. At the exit ofthis and all of the compressors C the flow passes serially by a pressuregage G, through two water cooled heat exchangers nd an automatic filtertrap comprising filter F and trap T before entering the secondcompressor C of that separa tion stage. Each filter trap T is connectedto return oil to its own compressor to maintain lubricant level. Eachcompressor unit is supplied independently with water for the cylinderhead and heat exchangers. The intercompressor pressures are monitored bygages G and limited by relief valves (not shown). The pressure at thefinal compressor C of each separation stage is adjusted by a backpressure regulator returning to a ballast tank (not shown) which alsoServes as a feed gas reservoir. It will be seen from this FIGURE 7showing that the inlet stream, depleted inlet or efliuent stream, andpermeate stream for each separation unit 100 are each monitored as topressure by gages G and as to rate of flow by flow rate measuringdevices R. In addition the dead end pressure in the casing assembly ofeach separation unit is monitored by gages G. Provision also was made(not shown) for recycling depleted gas or eflluent from each of thesecond and third separation stages and for analyzing the composition ofthe stream moving in any flow line. It will be apparent from FIGURE 7that the feed stream moves through the three compressor units Cassociated with the first separation stage and is passed via conduit 315through the interior of the hollow filaments of the first separationstage unit 100, the depleted stream leaving the interior of the hollowfilaments then passing through conduits 316 and 317 to be recycled orvented. The permeated stream is removed from the casing assembly of thefirst separation stage unit by conduit 318 and supplied to the threecompressors associated with the second separation stage unit. The streamfrom these compressors is supplied as an inlet stream via conduit 332 tothe interior of the hollow filaments of the second separation stage unit100, the depleted stream leaving the interior of the hollow filaments ofthis unit through conduits 333 to be recycled or vented. The permeatestream is removed from the casing assembly of the second separationstage unit via conduit 334 and supplied to the three compressorsassociated with the third separation stage unit 100. The stream fromthese compressors is supplied as an inlet stream via conduit 349 to theinterior of the hollow filaments of the third stage separation unit 100,the depleted stream leaving the interior of the hollow filaments of thisunit through conduits 350, 351 to be recycled or vented as desired. Thepermeate or final product stream is removed from the casing assembly ofthe third stage separation unit via conduit 352 and through another backpressure regulator unit R.

In operating the FIGURE 7 system an analyzer unit analyzing thepermeated product of the third stage separation unit adjusts the setpoint of a second analyzer unit analyzing the recycled stream from thesecond stage separation unit which in turn controls the rate of flow ofthis recycled stream. The rate of flow of the efliuent streams (whenrecycled) is controlled by valves V. This mode of operation hasadvantages since the composition of the third stage permeate productstream does not change as quickly or as much in response to changes insecond stage recycle flow rate as does the composition of either thesecond stage recycle or permeate stream. In a somewhat less desirablevariation of operation of this three stage system, the flow of recyclegas from the third stage is controlled in response to changes in itscomposition. This variation is less desirable because the volume of thisthird stage recycle gas is considerably smaller than the volume of thesecond stage recycle gas and because it changes much less in compositionwith changes in its flow rate because it contains an appreciably higherconcentration of more permeable components. However, this three stagesystem is very eflective in separating a product gas of very high purityfrom a feed gas of moderate purity, such as a very pure helium from amixture containing about 40% to about 70 helium. In such an arrangement,a countercurrent sweep gas may be used in the first stage unit or units,using depleted effluent gas from the first stage rather than the initialfeed mixture.

FIGURE 8 shows a separation system which may be viewed as a three stagesystem utilizing separation units similar to that shown in FIGURE 1 inwhich the efiluent or depleted inlet stream from the first stagearrangement is stripped or treated in an auxiliary stage. The feedstream, entering through conduit 430 passes through a filter and thenvia conduit 431 into the interior of the hollow filaments of the firststage permeation unit 100.

The depleted stream or effluent coming from the interior 2 of the hollowfilaments of the first stage permeation unit is conducted by conduit 432into the interior of the hollow filaments of the auxiliary stagepermeation unit 100. The depleted stream or effluent from the interiorof the hollow filaments of the auxiliary stage permeation unit is ventedor otherwise disposed of via conduit 433. A portion of this effluentstream is supplied by conduit 434 into the casing assembly of theauxiliary stage permeation unit as a sweep gas. This sweep gas and gaspermeated outwardly through the hollow filaments of the auxiliary stageunit is carried via conduits 435, 438 to a deoxo unit where it isreacted with air to remove any hydrogen by forming water therewith, thewater being removed in the dryer unit. A portion of the sweep gas andpermeated gas from the casing assembly of the auxiliary stage unit ispassed into the first stage unit casing assembly as a sweep gas byconduit 436. This sweep gas and permeated gas from the first stage unitcasing assembly are carried by conduit 437 to join the stream carried byconduit 435, moving to the deoxo unit. After passing through the deoxounit and dryer units this stream is supplied to the compressor Cassociated with the second stage permeation unit or units by conduit441. The

points adjacent the casing assembly ends in the casing assembly of thethird stage unit. This depleted or efiluent stream is removed from thecasing assembly of the third stage unit at a point intermediate the endsof the assembly and recycled via conduit 445 to the inlet stream of thesecond stage unit. The gas stream permeated inwardly through the hollowfilament membranes of the third stage permeation unit is collected andcarried away from the interior of the hollow filaments, as shown, byconduits 454, 455, 456 as a final permeate product, compressed at afinal compressor C and led to storage or use via conduit 457.

In operating this FIGURE 8 system, a fluid mixture containing arelatively high concentration of the more permeable components is fed tothe first stage permeation are mixed with the recycled efiiuent streamfrom the third stage unit, and the permeated fluid from the second stageis further concentrated or enriched in the third stage. In controllingthis system, the flows of sweep gas are regulated to obtain a desiredlow concentration in the depleted effiuent from the auxiliary stage. Therecycled effluent stream from the third stage is adjusted to obtain thedesired high concentration of the permeated product. This system isparticularly useful when the feed fluid contains a relatively highconcentration of an especially valuable more permeable component, suchas in the recovery of over 95% of the helium from a 60% helium mixtureas a 99.9% or higher purity product.

The data given in the following tables (Table I and Table II) isrepresentative of the physical features (Table I) and operatingconditions and values (Table II) typical of a system such as that shownin FIGURE 8 operating to produce 1 million cubic feet of helium per dayat 14.7 p.s.i.g. and 70 F. from a feed gas as indicated. The feed gascomposition is composed of helium, nitrogen,

methane, and hydrogen in the percentages indicated in "Table II. Thehollow filament membrane composition is as-spun poly(ethyleneterephthalate).

stream then is supplied as an inlet stream via conduits TABLE I 443,444, 446, and 447, to two points adjacent the casing stage Amman SecondThlrd assembly ends in the casing assembly of the second stage 15 15 2020 unit 100. This depleted inlet stream is removed from the Hollowfilament GD. 0 casing assembly of the second stage unit at a pointintergfff ffi g mediate the ends of the assembly and recycled to thetraction, ercent 2s 2s 2s 2s inlet stream of the first stage unit bymeans of conduit 10 10 1O 10 442. The gas stream permeated inwardlythrough the Total number offilaments A hollow filaments of the secondstage unit is collected and gg 1,060 322 carried away from the interiorof the hollow filaments, P(inches) 1g 1% ermeation separa ion uni s asshown, by conduits 448, 449 and led via conduit 450 Operatingtemperature (0 40 4O 40 40 to the compressor C associated with the thirdstage perme- Feed or inlet to units ation unit. From this compressor thestream is supplied Interior hollow filaments. as an inlet stream viaconduits 451, 452, 453 to two zcasmg assembly- TABLE II Proe. point No.Proc. point descr. Oper. Percent Percent Percent Percent Percent lercentFig. 8 Fig. 8 press. Flow He 2 CH4 2 2 B206 401 Init.feed 1,400 1,18858.5 39.4 1.8 0.3 0 1. 6X10 415 1,188 58.5 39. 4 1.8 0. 3 0 1. 0X10- 4151, 329 58. 5 39. 4 1.8 0. 3 0 1. 6X10- 315 552 3. 0 92. 3 4. 1 015 0. 550 215 499. s 0. 12 95. 53 4. 3 7 10- .040 0 Aux stage pmeate. 15 52.236.9 59.3 3.5 0.15 0.148 0 Stage 1 prneate 15 777 97. 0 2. 30 0.10 0. 4s.01 0 Feed to deoxo unit. 15 829.2 93. 0 0.10 0.30 0. 45 0.185 0 Feed todryer unit 15 838.8 02. 6 7. 0 0.30 00012 0. 040 0. 46 Air to deoxo 159.6 0 79 0 0 21 0 15 335. 2 92. 0 7. 0 0.36 00012 0. 045 0 425 335. 292. 0 7. 0 0. 30 00012 0. 045 0 425 73. 6 9s. 0. 9a 0. 00 0002 0. 022 0425 912. 0 93. 0 6. 5 0. 23 00013 0. 044 0 415 58. 4 39. 22 2. 1 000230. 27 0 15 772.8 99. 39 0. 1 005 00011 0024 0 435 772. s 99. 30 0. 1 00000011 .0024 0 p 15 594. 2 99. 99s 0015 0001 .0001 00012 0 419 Product4,000 094.2 99.993 .0015 .0001 .0001 00012 0 1 P.s.i.a. 1 Flow ins.e.f.m.

FIGURE 9 shows a preferred four stage separation system embodyingprinciples of the invention and utilizing in each stage one or moreseparation units of the general type shown in FIGURE 1. The feed orinlet stream, entering the system through conduit 501 passes through apressure regulating valve 502 and a control valve 504 actuated by anautomatic controller 545 for final feed stream pressure control and thenvia conduit 505 into the interior of the hollow filaments of the firststage permeation unit 100. The depleted stream or efiluent coming fromthe interior of the hollow filaments of the first stage permeation unitis conducted by conduit 506 to a control valve 507 actuated by anautomatic controller 532 for effluent pressure control. From valve 507this stream passes through conduit 508 to vent, recycling, or otherdisposition. A portion of the feed stream is diverted through a flowsensing device 534, conduit 533, pressure regulating valve 541, conduit539, control valve 538, and conduit 540 into the casing assembly of thefirst stage permeation or separation unit 100 as a sweep stream. Thissweep stream and the fluid permeated outwardly through the hollowfilaments of the first stage permeation unit is carried from the casingassembly of the unit by conduit 509 to compressor unit C1 and thence viaconduit 510 into the interior of the hollow filaments of the secondstage permeation unit 100. The depleted stream or eflluent coming fromthe interior of the hollow filaments of the second stage separation, orpermeation, unit is carried via conduit 511, control valve 557, andconduit 591 as a recycle stream to join with the inlet stream suppliedby conduit 505 to the interior of the hollow filaments of the firststage separation unit. The fluid permeated outwardly through the hollowfilaments of the second stage sepration unit is carried out of thecasing assembly of this unit by conduit 513 to compressor unit C2. Fromcompressor unit C2 this stream is supplied as an inlet stream viaconduit 514 into the casing assembly of the third stage separation unit100 at two spaced inlet points each adjacent one end of this casingassembly. The depleted stream or effluent from the casing assembly ofthe third stage separation unit is removed therefrom at a point on thecasing assembly between the two inlet points by conduit 515 and passesthrough pressure regulating valve 516, and conduit 517 to be recycledinto the inlet stream to the second stage separation unit carried byconduit 509. The stream of fluid which permeates inwardly through thehollow filaments of the third stage separation unit is removed from bothends of the interior of the hollow filaments and the unit by means ofconduits 518, 519 and carried via conduit 520 to compressor C3. Fromcompressor unit C3 this stream is supplied as an inlet stream viaconduit 521 into the casing assembly of the fourth and final stageseparation unit at two spaced inlet points each adjacent one end of thecasing assembly. The depleted or eflluent stream from the casingassembly of the fourth stage separation unit is removed therefrom at apoint on the casing assembly intermediate the two inlet points and movesfor recycling through conduit 522, pressure regulating valve 523, andconduit 524 to be recycled into the inlet stream to the third stageseparation unit carried by conduit 513. The stream of fluid whichpermeates inwardly through the hollow filaments of the fourth stageseparation unit is the final permeate product and is removed from bothends of the interior of the hollow filaments and the unit by means ofconduits 525, 526 and carried to storage or use by conduit 527. Thecomposition, or concentrations of the permeate product stream ispreferably continuously monitored by analyzer unit 578.

Each compressor unit is provided with a by-pass vacuum breakerarrangement as shown to control the pressure of the permeate streams.

The flow rates of the eflluent streams from the third and fourth stageseparation units were controlled by control valves 566 and 575, inconduits 567 and 576 respectively, to maintain the desired concentrationor compositions of these streams and of the final permeate product.

The system is provided with process control unit 551 which alternatelyanalyzes the eflluent stream concentration or composition leaving thefirst stage separation unit and the recycled stream concentration orcomposition leaving the second stage separation unit. A bleed line orconduit 560, having a pressure regulating valve 561 therein connects theeflluent stream in conduit 506 to unit 551 for analysis and a bleed line562 having pressure regulating valve 563 therein connects the recyclestream in conduit 511 to unit 551 for analysis. A signal representativeof the analysis of effluent (concentration or composition) in conduit506 is transmitted via conduit 550 to controller unit 547 which comparesthe signal with the desired or set-point concentration or compositionand generates an error or difference signal which is transmitted tocontroller unit 536. A rate of flow signal generated by flow sensingdevice 534 is transmitted to controller unit 536. With these two inputs,controller unit 536 actuates control valve 538 to maintain a desiredpredetermined concentration or composition in the effluent stream fromthe first stage separation unit. A signal representative of the analysisof recycle concentration or composition in conduit 511 is transmittedvia conduit 552 to control unit 553 which compares the signal with thedesired or set-point concentration or composition and generates an erroror difference signal which is transmitted to controller 555. A pressuredifference signal generated by pressure sensing device 559 connectedacross conduits 511 and 510 is transmitted to controller 555. With thesetwo inputs, controller unit 555 actuates control valve 557 to controlthe flow in conduit 511 and maintain a desired predeterminedconcentration or composition in the recycled effluent stream from thesecond stage separation unit.

Summarizing generally the operation of the FIGURE 9 system, the flow ofsweep fluid to the casing assembly of the first stage separation unit isadjusted by means of control valve 538- and controller units 547 and 536to maintain a predetermined low concentration, or composition, of themore permeable components in the depleted effluent carried by conduit506. In addition, the flow of either the second stage recycle stream,the third stage recycle stream, or the fourth stage recycle stream isadjusted in response to changes in the concentration, or composition, ofthe second stage permeate stream, the third stage permeate stream, orthe fourth stage permeate product stream. The preferred arrangement asillustrated in FIGURE 9 is to control the rate of the second stage unitrecycle stream to maintain a desired high concentration of the morepermeable component in the fourth stage permeate product stream. Such asystem with this process of operation is especially useful in recoveringa high fraction of a high purity product from a fluid mixture containinga low concentration of a more permeable component, as for example inrecovering helium from natural gas.

A pilot plant for recovering helium from natural gas using a four stagesystem embodying principles of this invention and of the type shown inFIGURE 9 was built and operated successfully. The system utilized hollowfilament membranes of poly(ethylene terephthalate) with outsidediameters of about 29.2 microns and inside diameters of about 15.5microns. The first stage arrangement contained a number of separationunits connected in parallel with a total of about 50 million hollowfilaments with effective lengths of about 200 cm. and an effective totalarea of about 73,000 square feet. The second stage arrangement containedabout 11 million hollow filaments with effective lengths of 75 cm. andan effective total area of about 617 square feet. The first and secondstage arrangements operated with the feed or inlet streams supplied intothe interior of the hollow filaments. The third and fourth stagearrangements operated with the feed or inlet streams supplied into thecasing assemblies outside of the hollow filaments, each having activefilament lengths of 86 cm., with about 10,400, and 3200 hollow filamentsrespectively and effective areas of about 66.4 and about 20.3 squarefeet respectively. This system included automatic control units foradjusting the fiow of sweep gas to the first stage arrangement inresponse to analysis of the depleted efiluent gas from the first stagearrangement, and for adjusting the flow of the second stage recyclestream in response to analysis of this recycle stream. In addition, thedesired concentration of the recycle stream was changed or controlled inresponse to changes in the helium content of the fourth stage finalpermeate product. This pilot plant system operated continuously withminor fluctuations in flow rates and gas mixture compositions under thefollowing conditions (minor losses and those due to sample streams arenot indicated) (Table III):

Likewise, an automatic control arrangement operating the system of thisinvention will adjust to a decrease in separation efficiency in anystage. Such a decrease can, for example, be caused by the development ofa leak in a separation membrane which permits feed gas to mix with theproduct gas in one of the separation stages. If such a leak develops inan intermediate stage, the resulting decrease in purity of the feed gasto the next stage will tend eventually to decrease the purity of theproduct gas from the last stage. The automatic control system will thenincrease the recycle rate to increase product purity to the desiredlevel and, as a necessary consequence, decrease the concentration ofmore permeable components in the recycle stream. Eventually thisdecrease in recycle stream purity will decrease the concentration ofmore permeable components in the recycle stream to the first stage andtend to decrease the concentration of more permeable components in thedepleted efiiuent gas. The auto- The effectiveness of the controlarrangement was tested by introducing upsets into the smoothly operatingprocess. The following upsets were introduced:

(a) The set-point for the desired helium concentration was changed forthe first stage depleted effluent and the second stage recycle streams,

(b) The rate of flow of the inlet stream to the first stage was changedby changing the pressure of the first stage depleted etfiuent stream,and

(c) The concentration of the feed or inlet stream to each stage waschanged.

In all cases, the automatic control arrangement functioned to restorethe process to equilibrium within a short time and the fourth stagepermeate product concentration remained unchanged.

The control arrangements of these separation systems of the inventionresult in the smooth operation of con tinuous permeation separationprocesses and systems with a minimum of upsets. With appropriateinstrumentation, the control system automatically adjusts itself to themany changes in process conditions which can occur during normaloperation of a commercial plant. For instance, an increase in theconcentration of the more permeable components in the feed gas will tendto increase their concentration in the depleted eflluent gas and in theproduct gas from the first stage. In response, the control system willincrease the amount of sweep gas to make operation of the firstseparation stage more efficient. The increased sweep gas will increasethe volume and change slightly the concentration of more permeablecomponents in the product gas from the first stage. The rate of flow ofthe second stage recycle stream then changes in response to changes inits concentration. These changes will eventually tend to increase thepurity of the product gas from the last stage. In response, the controlsystem will reduce the recycle rate from one of the stages. When thesystem reaches equilibrium, the net result will be maintenance of thedesired low concentration of more permeable components in the depletedefiiuent gas and production of a product gas of the desired high purityat a faster rate.

matic control arrangement disclosed will react to change the amount ofsweep gas to restore the depleted effluent gas to its desiredcomposition.

Another frequent advantage of the control technique and arrangement ofthis invention is a reduction in the number of stages required in amultistage process for separating the components of a gas mixture fromthe number required by similar processes of the prior art. Thisreduction in the number of stages results partly from operation of theinitial stripping and later enriching stages at high efiiciency andpartly from operation of the process with recycle streams moreconcentrated in the more permeable components than the feed streams withwhich they are mixed. The recycle streams will normally make up only asmall or moderate fraction of the total feed to any stage, but theconcentration of the more permeable components in the recycle stream mayin the early stages be from two to over ten times the concentration inthe feed stream with which it is mixed, so the mixture has asignificantly increased purity and therefore permeates more rapidly togive a product of increased purity. Similarly in the later stages, therecycle stream may have from half to one-tenth the concentration of theless permeable components and may make up from a small fraction to amajor fraction of the total feed to a stage. The result is again afaster permeation of a significantly more pure product.

A corollary advantage of the control arrangements and technique of thisinvention is a reduction in the membrane areas needed in all stages inproduction of a desired amount of a product gas of desired purity.Operation with recycle streams more pure than the streams with whichthey are mixed implies etficient utilization of the membrane areapresent.

Another corollary advantage is reduced installation and operating costsbecause of the reduced number of stages and the reduced membrane areaper stage. Operation with the control arrangement of this inventionresults in changes in the amount of first stage permeate almost inproportion to changes in the feed gas composition, and

17 any required changes in membrane area can be made in the laterstages, where the addition or removal of a single permeation unit has arelatively large effect on the capacity of the plant.

Operation of the enumerated gas operation processes and systems of thisinvention with tube-side feed, or feed to the interior of the hollowfilaments in the first or stripping stages has the unexpected advantageof a very large difference in the efiiciency of the separation obtained.This greater efficiency results from the improved contact between thefeed gas and the membrane obtained with tubeside feed and the morefavorable partial pressure differences obtained with improved contact,low permeate pressure, counter current flow, and the use of sweep gas.The practical effect is a very significant decrease in the membrane arearequired at any given production level.

Operation of the processes and systems of this invention with shell-sidefeed, or feed into the casing assembly outside of the hollow filaments,in the final or enriching stages without a sweep stream has theunexpected advantage and result that reduced permeation rates anddecreased permeate purities resulting from imperfections anddeficiencies of the hollow filaments are greatly reduced or completelyeliminated. The technical basis for this unobvious result is describedin the following discussion.

With tube-side feed, or feed into the filament interiors, a pluggedhollow filament is filled with stationary gas derived from either thefeed mixture or the efiluent mixture. As this gas becomes depleted bypermeation of the more permeable components, the concentration of lesspermeable components increases and significant amounts permeate toreduce the concentration of more permeable components. The result isdecreased permeate purity and reduced permeate. volume because of theplugged hollow filament. With shell-side feed, or feed into the casingassembly, and countercurrent operation, a hollow filament which isplugged near the feed end of the apparatus is, in effect, plugged atboth ends since countercurrent operation involves removing permeated gasfrom the hollow filaments only at the feed end of the apparatus. Ahollow filament which is plugged near the end of the apparatus fromwhich the depleted effluent gas is removed is, conversely, notsignificantly different from other hollow filaments in the apparatus.The net effect of plugged hollow filaments with shell-side feed is,therefore, a small reduction in the amount of permeate withoutsignificant reduction in concentration.

With tube-side feed, restricted flow by partial plugging increases timeof contact between the feed gas and the membrane and therefore increasesthe fraction permeated and reduces the purity of the permeate. Theeffect of the flow restriction on the quantity of the permeate willdepend on its location. If the restriction is near the end of theapparatus from which depleted effluent is withdrawn, the averagepressure inside the partially plugged hollow filament is increased withlittle change in permeate volume but permeate concentration isconsiderably decreased due to the longer contact time resulting fromslower flow through the hollow filament.

With shell-side feed, partially plugged hollow filaments have littleeffect on permeate purity or volume because they have little effect onthe pressure or flow rate of the low pressure, low density permeate.

Hollow filaments smaller than average have much the same effects aspartially plugged hollow filaments, reducing permeate purity and volumewith tube-side feed but not with shell-side feed.

With tube-side feed, hollow filaments larger than average permit fasterflow of the feed gas, reduce contact time to reduce the fractionpermeated, increase permeate purity, and increase the concentration ofthe more permeable components in the depleted effluent. With shell-sidefeed,

hollow filaments larger than average provide more-thanaverage surfacearea, increase permeate volume, and slightly increase permeateconcentration because of increased partial pressure differences due tolower permeate pressure.

With tube-side feed, a broken hollow filament is especially harmful,greatly increasing the volume of permeate and reducing its purity. Boththe feed gas and the depleted efiluent gas are at higher pressure thanthe permeate, so both flow through the open ends of a broken hollowfilament to pass relatively large volumes of feed or effluent gas intothe permeate space. Only a few broken hollow filaments per thousandtherefore greatly reduce permeate purity and increase its volume. Withshell-side feed, one end of each broken hollow filament is not used andthe amount of feed gas passing through the other end is reduced by thepressure drop in the length of hollow filament between the break and thepermeate exit. The advantage of shell-side feed is then to reduce theamount of feed gas passing into the permeate space by more than half.

Another unexpected advantage of shell-side feed in enriching stages isreduced danger of breaking hollow filament membranes with excessivepressures, less stringent requirements for control of operatingpressure, and greater freedom in varying the operating pressure tobalance the output of successive stages in a multistage process. Withtube-side feed in enriching stages, the filament wall thickness 'whichgives optimum high productivity and efiicient separation at anyparticular pressure is frequently small enough to leave only a smallmargin of safety between the operating pressure and the threshold burstpressure at which a small fraction of the filaments. will burst.Tube-side feed stages must, therefore, be operated within a narrow rangeof pressures for efficient use of their membrane areas without danger ofbursting the filaments. With shell-side feed on the other handconsiderably higher pressures can be used without danger of filamentcollapse. The amount of permeate obtained from a stage can then beconveniently varied by changing the operating pressure and adjusted tomatch and balance the amounts of gas handled in successive stages of theprocess. The resulting freedom in operating the process greatly reducesthe size of the system and the complexity of the control arrangementrequired.

As an illustrative example of this, when the four stage system shown inFIGURE 9 is used in the described operation to produce 99.99+% heliumfrom natural gas containing less than 1% helium With feed into thehollow filaments of the first two stages and into the casing assembliesoutside the hollow filaments in the last two stages, calculationsindicate that without this preferred arrangement, the system wouldrequire an additional stage, larger effective membrane surface area, andgreater power for compression. With feed to the interior of the hollowfilaments in all stages, an additional initial enriching stage would berequired with a moderate increase in effective membrane area butrequiring also a more significant increase in power for compression.With feed into the casing assembly outside of the hollow filaments inall stages, an additional final stage lWOllld be required with a largeincrease in effective membrane area but a less significant increase inpower for compresson.

Feed to the interior of the hollow filaments is preferred in initialseparation stages when the feed gases contain less than about 25% of themore permeable components and is more preferred and advantageous whenthis percentage is less than about 5 Feed in to the casing assembly ispreferred for final separation stages when the feed gases contain morethan about of the more permeable components and is more preferred andadvantageous when this percentage is more than about It has beenindicated in the preceding descriptions of the multi-stage systemsembodying features of this invention that a given separation stage, orseparation stage 19 arrangement, may comprise a number of separationunits connected in parallel. An illustrative multi-unit stagearrangement of this type embodying principles of the preent invention isshown in FIGURE 9a. This arrangement will be described as representativeof an initial stage of the FIGURE 8 helium separation system. In thisfigure, the feed stream passes through conduit 620, pressure regulatingvalve 605, and conduit 621 from which it is divided and flows throughconduits 636, 644, and 651 to control valves 637, 645, and 652respectively, and thence via conduits 638, 646, and 653 respectively tothe interior of the hollow filaments of separation units A, B, and Crespectively. The depleted eflluent streams from the interior of thefilaments of separation units A, B, and C move via conduits 639, 647,and 654 respectively, control valves 602a, 602b, and 6020 respectively,valves 641, 649, and 656 respectively, and conduits 642, 650, and 657respectively, and thence join in conduit 643 to proceed through pressureregulating valve 606 to vent a recycle. A portion of the feed stream inconduit 621 is led off by conduit 622 through valve 607 to conduit 623from which it is divided and flows through conduits 624, 628, and 632respectively to valves 625, 629, and 633 respectively, thence viaconduits 626, 630, and 634 respectively to valves 601a, 6011), and 6010respectively, from which conduits 627, 631, and 635 carry the streamsinto the casing assemblies of separation units A, B, and C respectivelyas sweep gas streams. The sweep gas streams and permeated streams arecarried from the casing assemblies of permeator units A, B, and C byconduits 658, 661, and 663 respectively, through valves 659, 662, and664 respectively, to join as one permeate product stream in conduit 660.Pressure drop sensing device 609 selectively senses the pressure dropacross the feed stream-efliuent stream of each separation unit by meansof conduits 670, 669, 668, 672, 674, and valves 673, 674, and 667.Pressure drop sensing device 608 senses the pressure drop across theentire stage is shown and the feed and effluent pressures are controlledby pressure regulating valves 605 and 606 respectively. In order toillustrate the types of variations in character istics possessed byseparation units of the same type and size the permeator units might bedescribed as follows:

Unit A.optimurn condition, all hollow filaments identical in size andshape, leak-free and unrestricted; thus, for a given operating pressureand feed gas concentration, its separation performance will have amaximum value.

Unit B.-marginal in quality, hollow filaments may be undersize, or ofnon-uniform sizes and/or shapes, may be plugged or restricted and mayhave leaks; thus when operated under same conditions as separation unitA, it will have reduced gas-handling capacity and both permeate andefliuent concentrations will be low.

Unit C.short hollow filaments and/ or oversize hollow filaments willhave a large capacity with high permeate and effluent concentrations.Its recovery of permeate gas will be low.

In the operation of the separation arrangement, it is desirable tomaintain permeate and effluent concentrations at some constant practicalvalue. And, in order to facilitate the adjustment of effective membraneare-a by adding or removing separation units to or from a given stagearrangement, it is very desirable that each individual separation unithave the same gas handling capacity and separation performance. Startingwith sweep stream valves 601a, 601b, and 601c fully closed and effluentstream valves 602a, 602b, and 6020 fully open, these objectives can beachieved by adjusting these valves to give the concentration required.Opening an efliuent stream control valve, such as 602a, will increaseseparation unit capacity and produce higher permeate and effiuent streamconcentrations; opening of a sweep stream control valve, such as 601a,will not affect capacity but will greatly reduce the effluent streamconcentration with only a small change in the permeate streamconcentration. When a given separation unit has been adjusted to givethe same gas handling capacity and separation performance as the others,the pressure drop across it as indicated or sensed by device 609 will bea measure of the quality performance of an individual separation unit.When, in a given unit set of valves, the sweep stream control valve,such as 601a, has been fully closed and the eflluent stream controlvalve, such as 602a has been fully opened, further adjustment cannot bemade and that unit should be removed from service.

A preferred arrangement for manufacturing the improved fluid separationapparatus of the invention is illustrated in FIGURES 1020 of thedrawings.

Continuous hollow filaments either in the form of monofilament ormulti-filament yarns are received in Wound packages P which arepositioned as shown on a supp y frame structure 700 (FIGURE 10) whichcomprises vertical members 701 interconnected with horizontal members702 preferably supported on wheels or rollers W. The filaments 111 oryarns from each package are led through suitable guide elements Ecarried by the supply frame structure to a suitable rotary apparatus 800which winds up the hollow filaments to simultaneously form a pluralityof skeins or hanks as shown in FIGURE 10. The rotary apparatus showncomprises a base 703, a vertical support 704, in which is journalled ahorizontal shaft 705. Shaft 705 is provided at one end with a pulleywheel 706 which is driven by an endless belt or chain 707. Shaft 705carries at its other end a circular member 708 which carries a pluralityof radially extending elements 709 each carrying a laterally extendinghank supporting element 710. Each element 710 is provided with cut outportions 711 for receiving the hanks 110 formed by winding up the hollowfilaments from the packages P.

After hanks 110 of suitable size are formed, rotation of apparatus 800is terminated and the hanks removed therefrom. Each hank is then engagedat two diametrically opposed positions by suitable means such as hookelements 720 and by manipulating the hook elements as shown in FIGURE 11the hank is flattened and elongated as shown to form a single compactbundle. While each bundle 110 is maintained in this configuration bysufficient tension applied to the hank elements 720, a porous flexiblesleeve 112, preferably of a circularly knit construction as described inthe preceding portions of the specification, is placed around the bundleand extending longitudinally along the bundle. As previously describedthe porous sleeve member 112 is of a construction such that tensionapplied to it longitudinally causes its transverse dimension, orperiphery to diminish. The sleeve member 112 may be applied by placingit in accordion like pleated or folded configuration on a smooth annularbushing or guide N as shown in FIGURE 12. Then, with the bushing andsleeve member surrounding one end of the filament bundle 110, thebushing is moved toward the other end of the bundle and the sleevemember allowed to pull off the bushing and engage the filament bundle ina snug constraining fit uniformly along the bundle length as indicatedin FIGURE 12. It will be seen that longitudinal tension applied to theends of the sleeve member will cause the reduction in the sleeve membertransverse periphery to compact and compress the hollow filaments into aclosely packed bundle or hank. As discussed previously, the flexibleporous sleeve member is formed of a sufliciently strong andabrasion-resistant material and construction not only to maintain thecompacting compressing action but also to protect the filaments duringassembly and operation of the apparatus.

A plurality of sleeve-encased filament bundles or groups prepared inaccordance with the preceding description are assembled and suspended atone end in a parallel vertically extending relationship as shown in FIG-URE 13 by means of an annular ring or a plate element 721 to which arehooked or secured the hook elements 720 which carry the sleeve-encasedfilament roups or

